Absorbent Article with Improved Garment-Like Character

ABSTRACT

A disposable absorbent article may include a chassis, an absorbent core, a pair of elastically elongatable ears and a pair of fastening tabs. The elastically elongatable ears and the fastening tabs have a transverse axis. The ears are connected to the chassis such that the transverse axis of the fastening tabs is located in specific portions of the article. The absorbent core is free of cellulosic fibers.

FIELD OF INVENTION

This invention relates to absorbent articles such as diapers havingfastener bearing ears that yield a more garment-like article. Theabsorbent article may have improved functional characteristics andcommunicative properties.

BACKGROUND OF THE INVENTION

It has long been known that absorbent articles such as conventionaltaped diapers offer the benefit of receiving and containing urine and/orother bodily exudates. To effectively contain exudates, the articleshould provide a snug fit around the waist and legs of a wearer.Absorbent articles are known to have a chassis comprising a topsheet, abacksheet, and an absorbent core. Absorbent articles such asconventional taped diapers generally include a front and a rear waistsection releasably and/or refastenably connected by a fastening system.The fastening system generally comprises an engaging member and areceiving member. The engaging member may be an adhesive tape, a hookbearing tape, a cohesive tape, or other like structure. The receivingmember may be an element or zone on the article that may receive theengaging member such as a polymer film landing zone (viz., for receiptof the adhesive or cohesive tape) or a loop bearing surface (viz., forreceipt of the hook bearing tape). The engaging member may be joined tothe receiving member thereby interconnecting the rear waist section tothe front waist section and thereby forming a waist opening and a pairof leg openings.

Current diaper designs frequently include the use of extensible ears.Back ears may extend laterally from the longitudinal edge of the rearwaist section of the chassis. The engaging member of the fasteningsystem may be attached to the back ear. In the case of front-fastened ortaped designs, when the fastening system is engaged to the receivingmember on the front waist region, the back ear serves as aninterconnecting member between the front waist section and the rearwaist section, which together form a waist opening and pair of legopenings. Back ears may be constructed to provide a degree of elasticrecovery. Elasticized back ears allow the diaper to provide a morecustomized fit. Furthermore, the elastic capability allows the diaper toadjust to the forces exerted by the wearer without causing permanentdeformation of the diaper or discomfort for the wearer of the diaper.Elasticity is typically imparted to the back ears by incorporatingelastic materials into the ear. Due to the high cost of elastomericmaterials, a common practice is to construct elastic ears as discretecomponents that are attached to the chassis (i.e., the main absorbentassembly to which other components may be disposed) resulting in amultipiece diaper. While this practice results in the efficient andcost-effective use of elastic materials, it is not without problems.

One problem seen in multipiece diapers is “tophatting.” A “tophat” is aportion of the front or rear waist region that extends beyond theuppermost edge of the front or back ear toward the waist edge of thediaper. When a multipiece diaper is appropriately worn, the waist edgeof the diaper in the front waist region and the rear waist region aresubstantially linear or slightly curvilinear. As the waist edgetransitions from the rear waist region to the attached back ear, thewaist edge may abruptly drop and then continue in a linear orcurvilinear manner following the upper edge of the back ear. This “drop”from the waist edge in the front waist region or the rear waist regionto the upper edge of the back ear may be one centimeter or greater. Whenworn, a taped diaper with the drop in the waist edge appears to have anotch cut from its side. The waist edge of such a diaper may have astair step-like appearance.

Tophatting may have an adverse impact on the fit characteristics of amultipiece diaper. Generally, a diaper exerts a circumferential line oftension around a wearer's torso. This tension may be a product of theelastic back ear being strained. With a multipiece diaper exhibiting atophat, the line of tension is located well below the waist edge becausethe line of tension is transmitted only along or through a continuous,unbroken path about the diaper. Since the tension-generating elasticizedear and fastening system are significantly remote from the waist edge,the line of tension is likewise remote from (e.g., generally lower than)the waist edge in the front waist region and rear waist region.

Fit and functionality problems may result from the line of tension beinglocated remotely from the waist edge. For example, the front waistregion and/or rear waist region of the diaper may exhibit sagging orfold-over. Sagging is the wrinkled, loose, gapped, or puckeredconfiguration that the diaper exhibits when it is not under tension.Fold-over is the inversion of at least a portion of the diaper such thata body-facing surface of the diaper becomes garment-facing. Similar tosagging, fold-over may occur when the portion of the diaper is not undertension. Fold-over and sagging may also impair the gasketing function ofthe waist edge. For example, the interface of the waist edge and thewearer's waist is susceptible to leakage particularly when the wearer isin a prone or supine position. Fold-over and sagging can reduce thesurface area of the diaper that is in close contact with the wearer atthis interface which may result in leakage.

Furthermore, fold-over and sagging are aesthetically undesirable.Fold-over and sagging result in a diaper that is sloppy looking duringwear. This, in turn, may communicate to the consumer that the diaper isof low quality which may be contrary to the high quality of functionalcharacteristics such as absorbency or leakage prevention.

Top-hating and the resulting lack of a smooth, continuous, andcircumferential waist edge communicate other unwanted messages to theconsumer or wearer of the diaper. For example, tophatting may be areadily visible signal that the product is a diaper. For many wearerssuch as children being toilet trained or incontinent youths and adults,a stigma is attached to having to wear a diaper. To alleviate thisconcern, the diaper should communicate a message of being garment-likeor underwear-like. In other words, it is desirable that the diaper notappear diaper-like. However, tophatting and discontinuous waist edgesare apparent signals of a diaper.

Accordingly, it would be desirable to provide a diaper having a back earthat eliminates or reduces tophatting in a multipiece diaper.Furthermore, it is desirable that the diaper exhibit a smooth,continuous, circumferential waist edge without discontinuities or drops.It is desirable that the diaper exhibit a line of tension, which isprovided at least in part by discrete ears, as close to the waist edgeas possible. It is also desirable that the diaper communicate a messageof being garment-like without the readily apparent visual cue (e.g.,waist discontinuity) of being a diaper.

SUMMARY OF THE INVENTION

The present invention relates to a disposable absorbent article thatcomprises a chassis having a front region with a front edge, a rearregion with a back edge, a crotch region between the front region andthe rear region, and a pair of opposing longitudinal edges. The chassiscomprises an absorbent core having front and back edges. The articlealso includes first and second elastically elongatable ears, each of thefirst and second ears having upper and lower edges and a transverseaxis, each of the upper and lower edges having proximal and distal ends.The first and second ears define a back section of the absorbent articlethat is present between the back edge of the chassis and a lineconnecting the respective lower ends of the lower edge of the first andsecond ears. The article also includes first and second fastening tabsrespectively connected the first and second elastically elongatableears, each of the first and second fastening tabs having upper and loweredges and a transverse axis, each of the upper and lower edges having aproximal end. The back section of the absorbent article includes aportion of the absorbent core having an average caliper of less thanabout 1.5 mm and the first and second elastically elongatable ears areconnected to the chassis such that the transverse axis of each of thefirst and second fastening tab is disposed between said back edge of thechassis and said back edge of said absorbent core.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of an exemplary diaper in a flat, uncontractedstate with back ears.

FIG. 1B is a plan view of an exemplary diaper in a flat, uncontractedstate with front ears and back ears.

FIG. 1C is a plan view of an exemplary diaper in a flat, uncontractedstate with back ears formed by a belt.

FIG. 2A is a perspective view of the diaper of FIG. 1A in a fastenedconfiguration as would be exhibited during wear.

FIG. 2B is a perspective view of the diaper of FIG. 1B in a fastenedconfiguration as would be exhibited during wear.

FIG. 3A is a magnified planar, side view of the diaper of FIG. 2A.

FIG. 3B is a magnified planar, side view of the diaper of FIG. 2B.

FIG. 4 is a perspective view of a suitable grip for use in the MetricTest Method.

FIGS. 5A-C depict suitable edge determinations.

FIG. 6 is a schematic body facing surface view of an absorbent articleaccording to one embodiment of the invention.

FIG. 7 depicts an elastically elongatable ear and a fastening tab.

FIG. 8 is a schematic cross section view of an example of an absorbentcore-suitable in one embodiment of the invention.

FIG. 9 is a schematic cross section view of another example of anabsorbent core suitable in one embodiment of the invention.

FIG. 10 is a schematic cross section view of another example of anabsorbent core suitable in one embodiment of the invention.

FIG. 11 is a schematic body facing surface view of an absorbent articlewith an absorbent core according to one embodiment of the invention.

FIG. 12 is a schematic body facing surface view of an absorbent articlewith an absorbent core according to another embodiment of the invention.

FIG. 13 is a schematic body facing surface view of an absorbent articlewith an absorbent core according to another embodiment of the invention.

FIG. 14 is a schematic body facing surface view of an absorbent articlewith an absorbent core according to another embodiment of the invention.

FIG. 15 is a schematic body facing surface view of an absorbent articlewith an absorbent core according to another embodiment of the invention.

FIG. 16 is an elevation view showing an apparatus for testing thebending stiffness of materials;

FIG. 17 is a front elevation view showing a plunger for use with theapparatus of FIG. 16;

FIG. 18 is a side elevation view showing a plunger for use with theapparatus of FIG. 16; and

FIG. 19 is a graph showing Peak bending load and slope calculation areason bending curve.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the following terms shall have the meaning specifiedthereafter:

“Tophat” is a portion of a front or rear waist region of a diaper thatextends beyond the uppermost edge of a front or back ear toward thewaist edge of the diaper.

“Disposable,” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise discarded in an environmentallycompatible manner).

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on pant-type diapers(i.e., a diaper having a pre-formed waist opening and leg openings suchas illustrated in U.S. Pat. No. 6,120,487), refastenable diapers orpant-type diapers, incontinence briefs and undergarments, diaper holdersand liners, feminine hygiene garments such as panty liners, absorbentinserts, and the like.

“Proximal” and “Distal” refer respectively to the location of an elementrelatively near to or far from the longitudinal or lateral centerline ofa structure (e.g., the proximal edge of a longitudinally extendingelement is located nearer to the longitudinal centerline than the distaledge of the same element is located relative to the same longitudinalcenterline).

“Body-facing” and “garment-facing” refer respectively to the relativelocation of an element or a surface of an element or group of elements.“Body-facing” implies the element or surface is nearer to the wearerduring wear than some other element or surface. “Garment-facing” impliesthe element or surface is more remote from the wearer during wear thansome other element or surface (i.e., element or surface is proximate tothe wearer's garments that may be worn over the disposable absorbentarticle).

“Longitudinal” refers to a direction running substantially perpendicularfrom a waist edge to an opposing waist edge of the article and generallyparallel to the maximum linear dimension of the article, Directionswithin 45 degrees of the longitudinal direction are considered to be“longitudinal”

“Lateral” refers to a direction running from a longitudinal edge to anopposing longitudinal edge of the article and generally at a right angleto the longitudinal direction. Directions within 45 degrees of thelateral direction are considered to be “lateral,”

“Disposed” refers to an element being located in a particular place orposition.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

“Film” refers to a sheet-like material wherein the length and width ofthe material far exceed the thickness of the material. Typically, filmshave a thickness of about 0.5 mm or less.

“Water-permeable” and “water-impermeable” refer to the penetrability ofmaterials in the context of the intended usage of disposable absorbentarticles. Specifically, the term “water-permeable” refers to a layer ora layered structure having pores, openings, and/or interconnected voidspaces that permit liquid water, urine, or synthetic urine to passthrough its thickness in the absence of a forcing pressure. Conversely,the term “water-impermeable” refers to a layer or a layered structurethrough the thickness of which liquid water, urine, or synthetic urinecannot pass in the absence of a forcing pressure (aside from naturalforces such as gravity). A layer or a layered structure that iswater-impermeable according to this definition may be permeable to watervapor, i.e., may be “vapor-permeable.” As is well known in the art, acommon method for measuring the permeability to water, urine, orsynthetic urine of the materials typically used in absorbent articles isa hydrostatic pressure test, also called a hydrostatic head test orsimply a “hydrohead” test. Suitable well known compendial methods forhydrohead testing are approved by INDA (formerly the InternationalNonwovens and Disposables Association, now The Association of theNonwoven Fabrics Industry) and EDANA (European Disposables And NonwovensAssociation).

“Extendibility” and “extensible” mean that the width or length of thecomponent in a relaxed state can be extended or increased.

“Elasticated” and “elasticized” mean that a component comprises at leasta portion made of elastic material.

“Elongatable material,” “extensible material,” or “stretchable material”are used interchangeably and refer to a material that, upon applicationof a biasing force, can stretch to an elongated length of at least 150%of its relaxed, original length (i.e. can stretch to 50% more than itsoriginal length), without complete rupture or breakage as measured byEDANA method 20.2-89. In the event such an elongatable material recoversat least 40% of its elongation upon release of the applied force, theelongatable material will be considered to be “elastic” or“elastomeric.” For example, an elastic material that has an initiallength of 100 mm can extend at least to 150 mm, and upon removal of theforce retracts to a length of at least 130 mm (i.e., exhibiting a 40%recovery). In the event the material recovers less than 40% of itselongation upon release of the applied force, the elongatable materialwill be considered to be “substantially non-elastic” or “substantiallynon-elastomeric. For example, an elastic material that has an initiallength of 100 mm can extend at least to 150 mm, and upon removal of theforce retracts to a length of at least 145 mm (i.e., exhibiting a 10%recovery).

“Elastomeric material” is a material exhibiting elastic properties.Elastomeric materials may include elastomeric films, scrims, nonwovens,and other sheet like structures.

“Outboard” and “inboard” refer respectively to the location of anelement disposed relatively far from or near to the longitudinalcenterline of the diaper with respect to a second element. For example,if element A is outboard of element B, then element A is farther fromthe longitudinal centerline than is element B.

“Pant” refers to disposable absorbent articles having a pre-formed waistand leg openings, A pant may be donned by inserting a wearer's legs intothe leg openings and sliding the pant into position about the wearer'slower torso. Pants are also commonly referred to as “closed diapers”,“prefastened diapers”, “pull-on diapers”, “training pants” and“diaper-pants.”

“Prefastened” refers to a disposable absorbent article that ismanufactured such that the fastening system is in an engaged or fastenedconfiguration.

“Consumer Commercial Good” refers to an item produced and distributed inlarge quantities and that the item may be purchased by a consumerthrough a retail establishment accessible to the public.

“Linear Projection” is the linear extension of an edge beyond the endpoint of the edge.

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of adiaper 20 of the present invention in a flat, uncontracted state (i.e.,without elastic induced contraction). The garment-facing surface 120 ofthe diaper 20 is facing the viewer. The diaper 20 includes alongitudinal centerline 100 and a lateral centerline 110. The diaper 20may comprise a chassis 22. The diaper 20 and chassis 22 are shown tohave a front waist region 36, a rear waist region 38 opposed to thefront waist region 36, and a crotch region 37 located between the frontwaist region 36 and the rear waist region 38. The waist regions 36 and38 generally comprise those portions of the diaper 20 which, when worn,encircle the waist of the wearer. The waist regions 36 and 38 mayinclude elastic elements such that they gather about the waist of thewearer to provide improved fit and containment. The crotch region 37 isthat portion of the diaper 20 which, when the diaper 20 is worn, isgenerally positioned between the legs of the wearer.

The outer periphery of chassis 22 is defined by longitudinal edges 12and lateral edges 14. The longitudinal edges 12 may be subdivided into afront longitudinal edge 12 a, which is the portion of the longitudinaledge 12 in the front waist region 36, and a rear longitudinal edge 12 b,which is the portion of the longitudinal edge 12 in the rear waistregion 38. The chassis 22 may have opposing longitudinal edges 12 thatare oriented generally parallel to the longitudinal centerline 100.However, for better fit, longitudinal edges 12 may be curved or angledto produce, for example, an “hourglass” shape diaper when viewed in aplan view. The chassis 22 may have opposing lateral edges 14 that areoriented generally parallel to the lateral centerline 110.

The chassis 22 may comprises a liquid permeable topsheet 24, a backsheet26, and an absorbent core 28 between the topsheet 24 and the backsheet26. The absorbent core 28 may have a body-facing surface and a garmentfacing-surface. The topsheet 24 may be joined to the core 28 and/or thebacksheet 26. The backsheet 26 may be joined to the core 28 and/or thetopsheet 24. It should be recognized that other structures, elements, orsubstrates may be positioned between the core 28 and the topsheet 24and/or backsheet 26. In certain embodiments, the chassis 22 comprisesthe main structure of the diaper 20 with other features may added toform the composite diaper structure. While the topsheet 24, thebacksheet 26, and the absorbent core 28 may be assembled in a variety ofwell-known configurations, preferred diaper configurations are describedgenerally in U.S. Pat. Nos. 3,860,003; 5,151,092; 5,221,274; 5,554,145;5,569,234; 5,580,411; and 6,004,306.

The topsheet 24 is generally a portion of the diaper 20 that may bepositioned at least in partial contact or close proximity to a wearer.Suitable topsheets 24 may be manufactured from a wide range ofmaterials, such as porous foams; reticulated foams; apertured plasticfilms; or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. The topsheet 24 isgenerally supple, soft feeling, and non-irritating to a wearer's skin.Generally, at least a portion of the topsheet 24 is liquid pervious,permitting liquid to readily penetrate through the thickness of thetopsheet 24. A particularly topsheet 24 is available from BBA Fiberweb,Brentwood, Tenn. as supplier code 055SLPV09U.

Any portion of the topsheet 24 may be coated with a lotion as is knownin the art. Examples of suitable lotions include those described in U.S.Pat. Nos., 5,607,760; 5,609,587; 5,635,191; and 5,643,588. The topsheet24 may be fully or partially elasticized or may be foreshortened so asto provide a void space between the topsheet 24 and the core 28.Exemplary structures including elasticized or foreshortened topsheetsare described in more detail in U.S. Pat. Nos. 4,892,536; 4,990,147;5,037,416; and 5,269,775.

The absorbent core 28 may comprise a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. Examples of suitable absorbent materials include comminutedwood pulp, which is generally referred to as air felt creped cellulosewadding; melt blown polymers, including co-form; chemically stiffened,modified or cross-linked cellulosic fibers; tissue, including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any other knownabsorbent material or combinations of materials. In one embodiment, atleast a portion of the absorbent core is substantially cellulose freeand contains less than 10% by weight cellulosic fibers, less than 5%cellulosic fibers, less than 1% cellulosic fibers, no more than animmaterial amount of cellulosic fibers or no cellulosic fibers. Itshould be understood that an immaterial amount of cellulosic materialdoes not materially affect at least one of the thinness, flexibility,and absorbency of the portion of the absorbent core that issubstantially cellulose free. Among other benefits, it is believed thatwhen at least a portion of the absorbent core is substantially cellulosefree, this portion of the absorbent core is significantly thinner andmore flexible than a similar absorbent core that includes more than 10%by weight of cellulosic fibers. The amount of absorbent material, suchas absorbent particulate polymer material present in the absorbent coremay vary, but in certain embodiments, is present in the absorbent corein an amount greater than about 80% by weight of the absorbent core, orgreater than about 85% by weight of the absorbent core, or greater thanabout 90% by weight of the absorbent core, or greater than about 95% byweight of the core. Non-limiting examples of suitable absorbent coresare described in greater details below.

Exemplary absorbent structures for use as the absorbent core 28 aredescribed in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735; 4,888,231;5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; 5,397,316; and5,625,222.

The backsheet 26 is generally positioned such that it may be at least aportion of the garment-facing surface 120 of the diaper 20. Backsheet 26may be designed to prevent the exudates absorbed by and contained withinthe diaper 20 from soiling articles that may contact the diaper 20, suchas bed sheets and undergarments. In certain embodiments, the backsheet26 is substantially water-impermeable. Suitable backsheet 26 materialsinclude films such as those manufactured by Tredegar Industries Inc. ofTerre Haute, Ind. and sold under the trade names X15306, X10962, andX10964, Other suitable backsheet 26 materials may include breathablematerials that permit vapors to escape from the diaper 20 while stillpreventing exudates from passing through the backsheet 26. Exemplarybreathable materials may include materials such as woven webs, nonwovenwebs, composite materials such as film-coated nonwoven webs, andmicroporous films such as manufactured by Mitsui Toatsu Co., of Japanunder the designation ESPOIR NO and by EXXON Chemical Co., of Bay City,Tex., under the designation EXXAIRE. Suitable breathable compositematerials comprising polymer blends are available from ClopayCorporation, Cincinnati, Ohio under the name HYTREL blend P18-3097. Suchbreathable composite materials are described in greater detail in PCTApplication No. WO 95/16746 and U.S. Pat. No. 5,865,823. Otherbreathable backsheets including nonwoven webs and apertured formed filmsare described in U.S. Pat. No. 5,571,096. An exemplary, suitablebacksheet is disclosed in U.S. Pat. No. 6,107,537. Other suitablematerials and/or manufacturing techniques may be used to provide asuitable backsheet 26 including, but not limited to, surface treatments,particular film selections and processing, particular filamentselections and processing, etc.

Backsheet 26 may also consist of more than one layer. The backsheet 26may comprise an outer cover and an inner layer. The outer cover may bemade of a soft, non-woven material. The inner layer may be made of asubstantially water-impermeable film. The outer cover and an inner layermay be joined together by adhesive or any other suitable material ormethod. A particularly suitable outer cover is available from CorovinGmbH, Peine, Germany as supplier code A18AH0, and a particularlysuitable inner layer is available from RKW Gronau GmbH, Gronau, Germanyas supplier code PGBR4WPR. While a variety of backsheet configurationsare contemplated herein, it would be obvious to those skilled in the artthat various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention.

The diaper 20 may include barrier cuffs 60 and/or gasketing cuffs 70.Gasketing cuffs 70 may also be referred to as outer leg cuffs, legbands, side flaps, leg cuffs, or elastic cuffs. Barrier cuffs 60 mayalso be referred to as second cuffs, inner leg cuffs or “stand-up”elasticized flaps.

The gasketing cuff 70 may be substantially inelastic or may beelastically extensible to dynamically fit at the wearer's leg. Thegasketing cuff 70 may be formed by one or more elastic members 72 (suchas elastic strands) operatively joined to the topsheet 24, backsheet 26,or any other suitable substrate used in the formation of the diaper 20.Suitable gasketing cuff construction is further described in U.S. Pat.No. 3,860,003

The barrier cuff 60 may span the entire longitudinal length of thediaper 20. The barrier cuff 60 may be formed by a flap 62 and an elasticmember 64 (such as elastic strands). The flap 62 may be a continuousextension of any of the existing materials or elements that form thediaper 20. In other embodiments, such as shown in FIG. 1, the barriercuff 60 may be a discrete element. In such embodiments, the barrier cuff60 comprising the flap 62 and the elastic member 64 may be formed thenjoined to the chassis 22 by a bond 65.

The flap 62 may comprise a variety of substrates such as plastic filmsand woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. In certain embodiments,the flap 62 may comprise a nonwoven web such as spunbond webs, meltblownwebs, carded webs, and combinations thereof (e.g., spunbond-meltblowncomposites and variants). Laminates of the aforementioned substrates mayalso be used to form the flap 62. A particularly suitable flap maycomprise a nonwoven available from BBA Fiberweb, Brentwood, Tenn. assupplier code 30926. A particularly suitable elastic member is availablefrom Invista, Wichita, Kans. as supplier code T262P. Further descriptionof diapers having barrier cuffs and suitable construction of suchbarrier cuffs may be found in U.S. Pat. Nos. 4,808,178 and 4,909,803.The elastic member 64 may span the longitudinal length of the barriercuff 60. In other embodiments, the elastic member 64 may span at leastthe longitudinal length of the barrier cuff 60 within the crotch region37. It is desirable that the elastic member 64 exhibits sufficientelasticity such that the barrier cuff 60 remains in contact with thewearer during normal wear, thereby enhancing the barrier properties ofthe barrier cuff 60. The elastic member 64 may be connected to the flap62 at opposing longitudinal ends. In certain embodiments, the flap 62may be folded over onto itself so as to encircle the elastic member 64.A bond 67 may be used to secure the folded section of the flap 62.

The barrier cuffs 60 and/or gasketing cuffs 70 may be treated, in fullor in part, with a lotion, as described above with regard to topsheets,or may be fully or partially coated with a hydrophobic surface coatingas detailed in U.S. application Ser. No. 11/055,743, which was filedFeb. 10, 2005.

The diaper 20 may include front ears 40 and/or back ears 42. The ears40, 42 may be extensible, inextensible, elastic, or inelastic. The ears40, 42 may be formed from nonwoven webs, woven webs, knitted fabrics,polymeric and elastomeric films, apertured films, sponges, foams,scrims, and combinations and laminates thereof. In certain embodimentsthe ears 40, 42 may be formed of a stretch laminate such as anonwoven/elastomeric material laminate or a nonwoven/elastomericmaterial/nonwoven laminate. Stretch laminates may be formed by anymethod known in the art. For example, the ears 40, 42 may be formed as azero strain stretch laminate, which includes at least a layer ofnon-woven material and an elastomeric element. The elastomeric elementis attached to the layer of non-woven material while in a relaxed orsubstantially relaxed state, and the resulting laminate is madestretchable (or more stretchable over a further range) by subjecting thelaminate to an activation process which elongates the nonwoven layerpermanently, but the elastomeric element temporarily. The nonwoven layermay be integral with at least a portion of the chassis 22, in which casethe elastomeric element may be attached to the nonwoven layer and thenon-woven/elastomeric element laminate is subsequently activated.Alternatively, the nonwoven layer may be a separate component, in whichcase the elastomeric element is attached to the nonwoven layer to formthe laminate, which is then coupled to the main portion. If one or morelayers of the side panel are provided separately, the laminate may beactivated either before or after attachment to the main portion. Thezero strain activation processes is further disclosed in U.S. Pat. Nos.5,167,897 and 5,156,793. A suitable elastic ear may be an activatedlaminate comprising an elastomeric film (such as is available fromTredegar Corp, Richmond, Va., as supplier code X25007) disposed betweentwo nonwoven layers (such as is available from BBA. Fiberweb, Brentwood,Tenn. as supplier code FPN332).

The ears 40, 42 may be discrete or integral. A discrete ear is formed asseparate element which is joined to the chassis 22. An integral ear is aportion of the chassis 22 that projects laterally outward from thelongitudinal edge 12, The integral ear may be formed by cutting thechassis form to have the projection.

A suitable diaper 20 having discrete back ears 42 and integral frontears 40 is shown in FIG. 1A. A suitable diaper having discrete back ears42 and discrete front ears 40 is shown in FIG. 1B, The front ears 40 mayhave a proximal edge 41 a, a distal edge 41 b, an upper edge 41 c, and alower edge 41 d. A portion of the front ear 40 adjacent to the proximaledge 41 a may be joined to the chassis 22 at a front bond region 45 a.The front bond region 45 a is the area within which one or more bondsjoin the discrete front ear 40 to the chassis 22. The front bond region45 a may comprise one or more bonds formed by any bonding method knownin the art such as adhesive bonding, pressure bonding, heat bonding, andthe like. If the front bond region 45 a comprises more than one bond,such as in an array or pattern of bonds, the front bond region 45 a isdefined by the are bounded by a polygon connecting the outermost bondsin each dimension. There may be a degree of overlap between the frontear 40 and the chassis 12 to allow for bonding. However, in otherembodiments, a larger portion of the front ear 40 may comprise a layer,element, or substrate of the chassis 22.

FIG. 1C depicts an embodiment of a diaper 20 having a belt 49 that formsboth back ears 42. In this embodiment, no front ears are present. Thebelt 49 may extend beyond the opposing longitudinal edges 12. The backears 42 may have a proximal edge 43 a, a distal edge 43 b, an upper edge43 c, and a lower edge 43 d. The proximal edge 43 a is taken asprojection of the longitudinal edge 12 on the belt 49.

As shown in both FIGS. 1A-C, the back ear 42 may be a discrete elementor a portion of a discrete element (e.g., the belt 45) that is joined tothe chassis 22. The back ears 42 may have a proximal edge 43 a, a distaledge 43 b, an upper edge 43 c, and a lower edge 43 d. A portion of theback ear 42 adjacent to the proximal edge 43 a may be joined to thechassis 22 at a back bond region 45 b. The back bond region 45 b is thearea within which one or more bonds join the back ear 42 to the chassis22. The back bond region 45 b may comprise one or more bonds formed byany bonding method known in the art such as adhesive bonding, pressurebonding, heat bonding, and the like. If the back bond region 45 bcomprises more than one bond, such as in an array or pattern of bonds,the back bond region 45 b is defined by the are bounded by a polygonconnecting the outermost bonds in each dimension. There may be a degreeof overlap between the back ear 42 and the chassis 12 to allow forbonding. However, in other embodiments, a larger portion or all of theback ear 42 may comprise a layer, element, or substrate of the chassis22.

The diaper 20 may also include a fastening system 50. When fastened, thefastening system 50 interconnects the front waist region 36 and the rearwaist region 38 resulting in a waist circumference that may encircle thewearer during wear of the diaper 20. The fastening system 50 maycomprises a fastener such as tape tabs, hook and loop fasteningcomponents, interlocking fasteners such as tabs & slots, buckles,buttons, snaps, and/or hermaphroditic fastening components, although anyother known fastening means are generally acceptable. Some exemplarysurface fastening systems are disclosed in U.S. Pat. Nos. 3,848,594;4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092; and 5,221,274. Anexemplary interlocking fastening system is disclosed in U.S. Pat. No.6,432,098. The fastening system 50 may also provide a means for holdingthe article in a disposal configuration as disclosed in U.S. Pat. No.4,963,140. The fastening system 50 may also include primary andsecondary fastening systems, as disclosed in U.S. Pat. No. 4,699,622.The fastening system 50 may be constructed to reduce shifting ofoverlapped portions or to improve fit as disclosed in U.S. Pat. Nos.5,242,436; 5,499,978; 5,507,736; and 5,591,152.

FIG. 1A depicts a fastening system 50 having an engaging member 52proximate the distal edge 43 b of the back ear 42 and a receiving member54 disposed in the front waist region 36 of the chassis 22. The engagingmember 52 is shown having an engaging surface 53 that may comprisehooks, loops, an adhesive, a cohesive, or other fastening member. FIG.1A depicts the engaging surface 53 as covering only a portion of theengaging member 52; however, in other embodiments, the engaging surface53 may cover substantially all of one or more faces of the engagingmember 52. The engaging member 52 may be joined to the back ear 42 at afastener bond region 47. The fastener bond region 47 is the area withinwhich one or more bonds join the engaging member 52 to the back ear 42.The fastener bond region 47 may comprise one or more bonds formed by anybonding method known in the art such as adhesive bonding, pressurebonding, heat bonding, and the like. If the fastener bond region 47comprises more than one bond, such as in an array or pattern of bonds,the fastener bond region 47 is defined by the are bounded by a polygonconnecting the outermost bonds in each dimension. In certain cases, suchas shown in FIG. 1B, the fastener bonding region 47 may be a line ofattachment.

The receiving member 54 may have a receiving surface 55 (as shown inFIGS. 1A and 1C) that allows for engagement of the engaging member 52.The receiving surface 54 may comprise hooks, loops, an adhesive, acohesive, or other fastening component that can receive the engagingmember 52, Suitable engaging member 52 and receiving member 54combinations include but are not limited to hooks/loop, hooks/hooks,adhesive/polymeric film; cohesive/cohesive, adhesive/adhesive; tab/slot;and button/button hole.

FIG. 2A is a perspective view of the diaper 20 of FIG. 1A in a fastenedconfiguration as would be seen during normal wear of the diaper. Theengaging surface 53 of the engaging member 52 may be mated with thereceiving member 54. The back ear 42 may span and connect the frontwaist region 36 and the rear waist region 38 to form a leg opening 86defined by a leg edge 88 (which includes a portion of the longitudinaledge 12 and the lower edge 44 d of the back ear 42) and a waist opening80 defined by a waist edge 82 (which includes a portion of the lateraledges 14 of the chassis 22 and the upper edge 44 c of the back ear 42).In embodiments where the back ear 42 is extensible or elastic, the backear 42 may be extended to provide a tensioning force to the diaper 20during wear.

FIG. 1B depicts a diaper 20 having front and back ears 40, 42. Thediaper may have a fastening system 50 comprising an engaging member 52and a receiving member 54. The engaging member 52 may be disposedproximate the distal edge 43 b of the back ear 42. The receiving member54 may be disposed proximate the distal edge 41 b of the front ear. Inthe FIG. 1B, the engaging member 52 is depicted as a tab member 56 andthe receiving member 54 is depicted as a slot member 58 with a slot 59therethrough. In a simple form, the fastening system 50 may be fastenedby passing the tab member 56 completely through the slot 59 of the slotmember 58. Once the tab member 56 has been passed through the slotmember 58, the tab member 56 may be rotated into a plane generallyparallel with the plane of the slot member 58 such that at least a partof the tab member 56 overlaps at least a portion of the slot member 58,FIG. 2B is a perspective view of the diaper 20 of FIG. 1B in a fastenedconfiguration as would be seen during normal wear of the diaper 20. Thetab member 56 and the slot member 58 are joined to form a leg opening 86defined by a leg edge 88 (which includes a portion of the longitudinaledge 12, the lower edge 41 d of the front ear 40, and the lower edge 43d of the back ear 42) and a waist opening 80 defined by a waist edge 82(which includes a portion of the lateral edges 14 of the chassis 22, theupper edge 41 c of the front ear, and the upper edge 43 c of the backear 42). In embodiments where the front ear 40 or the back ear 42 isextensible or elastic, the ear 40, 42 may be extended to provide atensioning force to the diaper 20 during wear. It should be recognizedthat other suitable engaging member 52 and receiving member 54combinations may be used instead or in addition to the tab and slot.

FIGS. 1A-C and 2A-B include as front tophat 99 a and/or a back tophat 99b. In FIG. 1A, the back tophat 99 b is shown in the rear waist region 38as the portion of the diaper 20 bounded by the upper edge 43 c of theback ear 42 and the lateral edge 14 in the rear waist region 38. Oncefastened, as shown in FIG. 2A, the diaper 20 may have a front tophat 99a in the front waist region 36. The front tophat 99 a is the portion ofthe diaper 20 bounded by the upper edge 41 c of the back ear 42 and thelateral edge 14 in the front waist region 36.

In FIGS. 1B and 2B, the front tophat 99 a is shown in the front waistregion 36 as the portion of the diaper 20 bounded by the upper edge 41 cof the front ear 40 and the lateral edge 14 in the front waist region36. The back tophat 99 b is shown in the rear waist region 38 as theportion of the diaper 20 bounded by the upper edge 43 c of the back ear42 and the lateral edge 14 in the rear waist region 38.

In FIG. 1C, the back tophat 99 b is shown in the rear waist region 38 asthe portion of the diaper 20 bounded by the upper edge 43 c of the backear 42 and the lateral edge 14 in the rear waist region 38.

FIG. 3A is a magnified planar, side view of the diaper 20 of FIG. 2Ashowing the back ear 42, a portion of the front waist region 36, and aportion of the rear waist region 38. FIG. 3B is a magnified planar, sideview of the diaper 20 of FIG. 2B showing the back ear 42, the front ear40, a portion of the front waist region 36, and a portion of the rearwaist region 38. To more precisely and quantitatively describe thetophats 99 a and 99 h, a number of metrics are shown. Suitable metricsinclude a Front Edge Displacement A, a Rear Edge Displacement C, an EarSpan Width B, an Ear Midpoint Width X, and a Receiving Member MidpointWidth Y. Several of the metrics are determined with reference to a firstproduct mark 1, a second product mark 2, and a lateral reference line 3.The receiving member 54 may include a longitudinal midpoint 48 a. Theengaging member may include a longitudinal midpoint 48 b. The method formeasuring the metrics and applying the product marks 1 and 2, thelateral reference line 3, the midpoints 48 a, 48 b to the diaper 20 isdiscussed below in the Metric Test Method section.

To address the problem of tophatting, it is desirable that the FrontEdge Displacement A and the Rear Edge Displacement C be reduced oreliminated. In certain embodiments, the Front Edge Displacement A may beno greater than about 1.0 mm. Alternatively, the Front Edge DisplacementA may be no greater than about 0.5 mm or about 0.3 mm. In certainembodiments, the Front Edge Displacement A may be about 0. In certainembodiments, the Rear Edge Displacement C may be no greater than about10 mm. Alternatively, the Rear Edge Displacement C may be no greaterthan about 7 mm, about 5 mm, about 3 mm, or about 1 mm. In certainembodiments, the Rear Edge Displacement C may be about 0. Anycombination of the aforementioned Front Edge Displacement A and RearEdge Displacement C is also within the scope of the invention.Furthermore, in certain embodiments, the sum of the Front EdgeDisplacement A and the Rear Edge Displacement C may be no greater thanabout 12 mm. Alternatively, the sum of the Front Edge Displacement A andthe Rear Edge Displacement C may be no greater than about 10 mm, about 5mm, about 3 mm, or about 1 mm. In certain embodiments, the sum of theFront Edge Displacement A and the Rear Edge Displacement C may be about0.

In other embodiments, it has been found that a ratio of the Front EdgeDisplacement A or Rear Edge Displacement C to the Ear Span Width B isvery important in consumer perception of tophatting and the resultingwaist edge discontinuity. For example, the waist edge discontinuity maybe less appreciable in a diaper with a larger Ear Span Width B ratherthan with a diaper having a smaller Ear Span Width B. In certainembodiments, the ratio of the Front Edge Displacement A to the Ear SpanWidth B (A/B) may be no greater than about 0.05. In certain embodiments,the ratio of the Front Edge Displacement A to the Ear Span Width B (A/B)is about 0. In certain embodiments, the ratio of the Rear EdgeDisplacement C to the Ear Span Width B (CB) may be no greater than about0.24. Alternatively, the ratio of the Rear Edge Displacement C to theEar Span Width B (C/B) may be no greater than about 0.20 or about 0.10.In certain embodiments, the ratio of the Rear Edge Displacement C to theEar Span Width B (CM) is about 0.

in other embodiments, it may be desirable that the combined Front EdgeDisplacement A and the Rear Edge Displacement C be minimized in relationto the Ear Span Width B. The sum of Front Edge Displacement A and theRear Edge Displacement C to the Ear Span Width B ratio ((A+C)/B) may beno greater than about 0.30. Alternatively, the combined Front EdgeDisplacement A and the Rear Edge Displacement C to the Ear Span Width Bratio ((A+C) B) may be less than about 0.20 or about 0.10. In otherembodiments, the combined Front Edge Displacement A and the Rear EdgeDisplacement C to the Ear Span Width B ratio ((A+C)/B) is about 0.

In other embodiments, it has been found that a ratio of the Front EdgeDisplacement A to the Ear Midpoint Width X is very important in consumerperception of tophatting and the resulting waist edge discontinuity. Forexample, the waist edge discontinuity may be less appreciable in adiaper with a larger Ear Midpoint Width X rather than with a diaperhaving a smaller Ear Midpoint Width X. In certain embodiments, the ratioof the combined Front Edge Displacement A and the Rear Edge DisplacementC to the Ear Midpoint Width X ((A+C)/X) may be less than about 0.30.Alternatively, the ratio of the combined Front Edge Displacement A andthe Rear Edge Displacement C to the Ear Midpoint Width X ((A+C)/X) maybe about 0.25, about 0.20, or about 0.10. In other embodiments, theratio of the combined Front Edge Displacement A and the Rear EdgeDisplacement C to the Ear Midpoint Width X ((A+C)/X) is about 0.

FIGS. 1-3 depict the back ear 42 being bonded to and extending from therear waist region 38 and designed such that the engaging member 52joined to the back ear 42 may engage the receiving member 54 disposed inthe front waist region 36. However, it should be readily apparent to oneskilled in the art that the back ear may be configured to be a front ear42 which may be bonded to and extend from the front waist region 36 anddesigned such that the engaging member 52 joined to the front ear mayengage the receiving member 54 disposed in the rear waist region 38. TheFront Edge Displacement A, Rear Edge Displacement C, Bar Span Width B,Ear Midpoint Width X, and the Receiving Member Midpoint Width. Y areequally applicable to a front ear.

Metric Test Method

This method describes a method to mark and capture physical referencepoints on diapers as they are pulled to known tensile force values witha calibrated programmable mechanical tensile tester. This method alsodescribes the process for making the appropriate distance calculationsusing spreadsheet software such as Microsoft Excel. These calculationsare based upon measurements of pixel x-y coordinates taken from digitalcamera images through the use of photo-analysis computer program.

A suitable tensile tester must be capable of pulling at a constantcrosshead rate of 127 mm/min. The tensile tester must be equipped with acalibrated load cell such that the tested load values are no less than1% of the calibration ranged of the load cell. A suitable tensile testeris a MTS Tensile Tester, Model 1/S available from MTS Systems Corp.,Eden Prairie, Minn. and loaded with a ION load cell. The tensile testerincludes two matching grips 410 a and 410 b as shown in FIG. 4. Eachgrips 410 a, 410 b includes a semi-cylindrical face 412 upon which asample may be mounted. The faces 412 are made from 1.50 mm thickstainless having a length L of 127 mm. The faces 412 have a diameter Dof 115 mm. Each face 412 is joined to a hook 414 that allow the grip 410to be joined to the tensile tested. The hook 414 runs the length L ofthe inside surface of the semi-cylindrical face. One grip 410 a isjoined to the load cell and movable crosshead of the tensile tester. Theother grip 410 b is joined to the non-moving base of the tensile tester.

All values reported below are an average of five random samples. Toensure the randomization of consumer commercial samples, the fivesamples are to be taken as follows:

-   -   (i) If the consumer commercial sample is sold individually        (i.e., one sample may be individually purchased), then five        consumer commercial samples are acquired.    -   (ii) If the consumer commercial sample is to be sold as a        plurality (i.e., several samples are purchased as a single        unit), then five pluralities are to be acquired. One sample from        each of the five pluralities is randomly chosen for testing.

Product Marks: Two product marks “+” are to be placed on the left side(i.e., the side of the product that would fall along the left side of awearer during normal wear of the sample) of each sample prior totesting. The product marks may be made using a fine tip permanent markeror like device. The first product mark 1, as shown in FIGS. 3A-B, ismade according to the following steps:

-   -   1. If the product has a fastener bonding zone 47 (as shown in        FIG. 3A-B), the first product mark is placed in the center of        the fastener bonding zone 47.    -   2, if the product has no fastener bonding zone 47, the first        product mark is placed in the center of the engaging surface 53.    -   3. If 1 or 2 are not available, the first product mark is placed        in the center of the engaging member 52.        The second product mark 2, as shown in FIGS. 3A-B, is placed in        the center of the back bond region 45 b. A lateral reference        line 3 is drawn through the first product mark 1 and the second        product mark 2; the line 3 terminates at the inboard and        outboard edge of the car/engaging member combination.

Metric Measurement: The Front Edge Displacement A, Rear EdgeDisplacement C, Ear Span Width B, Ear Midpoint Width X, and theReceiving Member Midpoint Width Y may be determined according to thedescription provided below and with reference to FIGS. 3A-B. Forpurposes of metric measurement and procedural steps, when measuring toor from an edge, the term “edge” means in order of preference:

-   -   1. A physical edge 510 of a sample 500 if said edge 510 is        linear and intersects with a line segment 512 to be drawn, as        shown in FIG. 5A,    -   2. If not 1, then a linear projection 514 from the physical edge        510 of the sample 500 if the physical edge 510 is substantially        linear, as shown in FIG. 5E.    -   3. If not 1 or 2, then a tangential line 516 drawn from the        outermost point 518 on the physical edge 510 of the sample 500,        as shown in FIG. 5C.

FIGS. 5A-C are provided to teach how the linear projection andtangential line should be drawn on a simple shape (e.g., sample 500).One skilled in the art will be able to apply these teachings to drawingthe linear projection and tangential line on the various edges of anabsorbent article.

The Front Edge Displacement A is the distance of a line segment drawnfrom (i) the intersection of the upper edge of the ear and the frontlongitudinal edge 12 a and perpendicular to (ii) the lateral edge 14 inthe front waist region 36, a linear projection of the lateral edge 14 inthe front waist region 36, or, for samples where there is no linearcomponent of the edge, a tangent line drawn from the edge. As shown inFIG. 3A, the Front Edge Displacement A is the distance between the upperedge 43 c of the back ear 42 and the lateral edge 14 of the front waistregion 38. As shown in FIG. 3B, the Front Edge Displacement A is thedistance between the upper edge 41 c of the front ear 40 and the lateraledge 14 of the front waist region 38.

The Rear Edge Displacement C is the distance of a line segment drawnfrom (i) the intersection of the upper edge of the ear and the rearlongitudinal edge 11 b and perpendicular to (ii) the lateral edge 14 inthe rear waist region 38 or a linear projection of the lateral edge 14in the rear waist region 38. As shown in FIGS. 3A and 38, the Rear EdgeDisplacement C is the distance between the upper edge 44 c of the backear 42 and the longitudinal edge 14 of the rear waist region 38.

The Ear Span Width B is the linear distance of a line segment drawn from(i) the intersection of the lower edge of a back ear with either thefront longitudinal edge 12 a or an edge of the front ear 40, whicheveris most outboard and (ii) the intersection of the rear longitudinal edge12 b and a lower edge of a back ear. As shown in FIG. 3A, the Ear SpanWidth B is the distance between (i) the intersection of the frontlongitudinal edge 12 a and the lower edge 43 d of the back ear 42 and(ii) the intersection of the rear longitudinal edge 12 b and the loweredge 43 d of the back ear 42. However, for side fastened diapers, suchas shown in FIG. 38, the Ear Span Width B is the distance of a linesegment drawn from (i) the intersection of the front longitudinal edge12 a and the lower edge 41 d of the front ear 40 and (ii) theintersection of the rear longitudinal edge 12 b and the lower edge 43 dof the back ear 42.

The Ear Midpoint Width X is the distance of the line segment drawn from(i) the first product mark 1 and perpendicular to (ii) the lateral edge14 in the front waist region 36 or a linear projection of the lateraledge 14 in the front waist region 36.

The Receiving Member Midpoint Width Y is the distance of the linesegment drawn from (i) a midpoint 48 of the receiving member 54 adjacentthe inboard edge of the engaging member 52 (when the receiving member 54and the engaging member 52 are in a fastened configuration) andperpendicular to (ii) the lateral edge 14 in the front waist region 36or a linear projection of the lateral edge 14 in the front waist region36. The longitudinal midpoint 48 of the receiving member 54 is themidpoint of a line segment drawn longitudinally from opposing lateraledges of the receiving member 54. In some instances such as shown in HG,3B, the receiving member 54 may be overlapped by the engaging member 52.In such instances, the midpoint 48 of the receiving member 54 is themidpoint of a line segment drawn longitudinally from the linearprojection of the opposing lateral edges of the receiving member 54 anddrawn adjacent to the inboard edge of the engaging member 52.

Procedural Steps: The metrics are measured according to the steps thatfollow:

-   1. A calibration ruler is placed in proximity to the grips. The    calibration ruler marked in millimeters is mounted so the ruled-face    of the ruler is on the same plane as the surface of the product    being measured.-   2. A digital camera is mounted on a tripod adjacent to the tensile    tester and positioned in such a way that the sample and calibration    ruler fill the camera's field of view as much as possible. The    camera is aligned vertically and horizontally with the surface of    the sample.-   3. The sample is marked with the two product marks and the lateral    reference line as described above,-   4. The sample is fastened to the sample's largest possible fastener    setting. The engaging member should be joined to the receiving    member such that a longitudinal midpoint of the engaging member is    aligned longitudinally, at the point of intersection, with a    longitudinal midpoint of the receiving member. The longitudinal    midpoint of the receiving member is the midpoint of a line segment    drawn longitudinally from opposing lateral edges of the receiving    member. The longitudinal midpoint of the engaging member is the    midpoint of a line segment drawn longitudinally from opposing    lateral edges of the engaging member. Additionally, the proximal    edge of the engaging surface should be aligned with the longitudinal    edge of the receiving surface. In samples not having a distinct    engaging surface or receiving surface, the engaging member and    receiving member of the sample should be fastened such that (i) the    lateral edges in the front and back waist regions are aligned    and (ii) the distal edge of the engaging member is placed 50 mm    inboard of the longitudinal edge of the front waist region or as far    outboard as possible while still maintaining engagement to the front    waist region, whichever results in the fastener being closer to the    longitudinal edge of the front waist region.-   5. The sample is mounted onto the grips of the tensile tester such    that the front waist region of the sample is approximately centered    on the movable grip and that the back waist region of the sample is    approximately centered on the stationary grip. The sample is mounted    sample so that the sample marks are facing the camera, all test    values are visible, the sample is at the same distance from the    camera as the ruler, and the sample is perpendicular to the camera's    field or view.-   6. The sample is pulled at a constant crosshead rate of 127 mm/min    and held in position for 10 seconds when the load reaches 200 grams.    A picture is taken.-   7. The sample is pulled at a constant crosshead rate of 127 mm/until    a load value of 1200 grams is reached. The crosshead is stopped and    a picture is taken.-   8. The crosshead is returned to the original position.

Using a computer imaging program capable of displaying pixel values inpictures (i.e., Adobe® Photoshop®), each picture taken at 1200 g load isanalyzed. For each picture, a line is drawn on the digital image foreach of the metrics (A, B, C, X, Y, and W). The pixel coordinates (x andy coordinates) for the end points of each drawn line are recorded. Aline is drawn on the calibration ruler between two marks that are 50 mmapart. The pixel coordinates for this line are recorded. The pixelcoordinates for endpoints of each metric and the calibration ruler areentered into an appropriate computer spreadsheet program (e.g.,Microsoft® Excel®). The spreadsheet may be programmed to computer thedistance between endpoints, as measured in pixels, according to thefollowing equation:

d=√{square root over ((x ₁ ² −x ₂ ²)+(y ₁ ² −y ₂ ²))}{square root over((x ₁ ² −x ₂ ²)+(y ₁ ² −y ₂ ²))}

where d=distance between two points (x₁, y₁) and (x₂, y₂). The distancein pixels for the calibration ruler, which is known to be 50 mm, can beuse to convert the distance in pixels of any of the metric measurementsinto a distance in millimeters. The spreadsheet is programmed to convertlength values based on pixel coordinates in millimeters.

The procedural steps are performed for the five duplicate samples. Thedistance values for each metric are averaged and the average isrecorded.

EXAMPLES

Example 1 is a suitable example of the present invention. The chassis ofthis present example is constructed according to the descriptionprovided for a containment assembly in U.S. Pat. No. 5,151,092. Theexample has two back ears joined along the opposing rear longitudinaledges of the chassis. The back ears comprise a trilaminate with twooutmost layers being a nonwoven available from BBA Nonwovens, Inc., OldHickory, Tenn. as code HEC FPN 332D. Disposed between the two nonwovenlayers is an elastic film available from Nordenia USA, Inc, Jackson, Mo.as code KG6361.100. A portion of the back ear is incrementally stretchedaccording to the zero strain activation processes disclosed in U.S. Pat.Nos. 5,167,897 and 5,156,793, The back ear further comprises an engagingmember which is a polymer film tab with a hook-bearing surface. Thehook-bearing surface has an approximate area of 3.8 cm². The tab extendsfrom the outboard edge of the back ear opposite the back ear edge thatis joined to the chassis. The example further comprises a rectilinearreceiving member disposed in the front waist region and on the garmentfacing surface of the chassis. The receiving member is a polymer filmpatch with fibrous loops on the garment-facing surface of the patch. Thepatch is available from Aplix Fasteners, Inc., Suffolk, UK as codeAN29R95327873. The patch measures approximately 13.5 cm×5.0 cm with thelong dimension running approximately parallel to the lateral edge of thechassis.

Example 2 is a commercially available comparative sample. The example isPampers Cruisers size 4 diaper available from The Procter & GambleCompany, Cincinnati, Ohio.

Example 3 is a commercially available comparative sample. The example isHuggies® Supreme® size 4 available from the Kimberly-Clark Corp.,Neenah, Wis.

Example 4 is a commercially available comparative sample. The example isBaby-Shaped®Huggies® size 4 available from the Kimberly-Clark Corp.,Neenah, Wis.

Test Results

A B C A + C X Y Example 1 0 (0) 45.2 (5.7)  5.7 (0.7) 5.7 32.5 (1.5)33.8 (1.1) Example 2 8.7 (2.8) 64.1 (7.7) 15.9 (1.4) 24.6 47.1 (2.4)46.3 (1.7) Example 3 5.2 (5.0) 49.0 (3.2) 17.8 (3.5) 23.0 40.4 (4.9)43.8 (3.5) Example 4 4.8 (2.6) 29.2 (2.1) 12.8 (2.5) 17.6 44.1 (1.3)47.4 (1.6)All measurements in millimeters. Standard deviation presented inparenthesis.

C/B (A + C)/B (A + C)/X Example 1 0.13 0.13 0.18 Example 2 0.25 0.380.52 Example 3 0.36 0.47 0.57 Example 4 0.44 0.60 0.40

In one embodiment schematically represented in FIG. 6, an absorbentarticle includes an absorbent core 28 that extends longitudinallybetween the front waist region 36 and the rear waist region 38, which isdisposed in a front section 128, a middle section 228 and a back section328 of the absorbent article. The absorbent core includes a front edge428, a back edge 528 and side edges 628. The front section 128 is thesection of the absorbent article that is generally disposed in the frontwaist region 36 of the chassis. The back section 328 is the section ofthe absorbent article that is disposed between the lateral back edge ofthe chassis and the transverse line A-A connecting the proximal ends ofthe lower edge of each of the left and right back ears 42. It should benoted that the back section 328 does not necessarily coincide with therear waist region 38 of the article. The middle section 228 is thesection of the absorbent article that is generally disposed between andinterconnects the front section 128 to the back section 328. In oneembodiment, at least part of an absorbent core is disposed in at leastone of the front section 128, the middle section 228 and the backsection 328 of the absorbent article. In one embodiment, an absorbentcore is disposed in the middle section 228 and extends into the at leastpart of the front section 128 and/or into the back section 328. In oneembodiment, the part of the absorbent core that is disposed in thefront, middle section, or the back section is substantially cellulosefree. In one embodiment the back section 328 comprises an absorbent corethat is substantially cellulose free. In one embodiment, at least one ofthe front section 128, the middle section 228 and the back section 328of the absorbent article comprises an absorbent core and has an averagecaliper of less than 1.5 mm, less than 1.25 mm, less than 1 mm, lessthan 0.75 mm or even less than 0.5 nm. In one embodiment, the backsection 328 of the absorbent article comprises an absorbent core and hasan average caliper of less than 1.5 mm., less than 1.25 mm, less than 1mm, less than 0.75 mm or even less than 0.5 mm. A suitable method tomeasure the average caliper of a section of an absorbent article isdiscussed below. Among other benefits, it is believed that an absorbentarticle having at least one of, or even all of its front, middle andback sections that are thin is much more flexible than a thickerabsorbent article while still maintaining its ability to absorb andretain body exudates. A thin absorbent article can more easily conformto the wearer's body shape and consequently, is more underwear-like. Inaddition, a thin absorbent article provides a snug fit around the waistand legs of a wearer. An absorbent article having a thin back sectionalso allows tensions (caused by the forces created by elasticallystretchable ears or side panels when the article is attached to thewearer) that are applied transversely on the article backsheet to becloser to the wearer's skin. Tensions that are applied in closeproximity to the wearer's skin can prevent the article from “sliding”down the wearer's lower back and buttocks, especially after one or moredischarges of body exudates. But it is also believed that when the frontand/or back sections of the article are thin, these sections may have atendency to fold-over when a longitudinal side of these sections issubjected to lateral forces. It is observed, for instance, that when acaregiver pulls on a tape tab (such as the one represented in FIG. 1A)for extending the back ear of the article, at least a portion of theback section of the article may fold-over inward or outward. Thefolding-over of the back section may cause discomfort to the wearer.Moreover, it may result in an inefficient use of the absorbent corepositioned in the portion that is folded-over and it may also causeleakage or exudates run-off if a portion of the back section is foldedoutward. Without intending to be bound by any theory, it is believedthat this folding-over of the hack section occurs when the outermostline of tension (resulting from an elongation of the back ear) islocated away from the lateral back edge of the chassis. It is alsobelieved that the distance between the outermost and innermost lines oftension affects the folding-over of the back section. One of ordinaryskill will appreciate that a relatively short distance between theoutermost and innermost lines of tension result in a concentration offorces over a relatively narrow area whereas a longer distance betweenthe outermost and innermost lines of tension result in a betterdistribution of the forces over a larger area. It is also believed thatan “abrupt” change in thickness (in the longitudinal direction) from theportion of the back section that includes the absorbent core to theportion of the back section that does not include the absorbent core maycreate a weakness or path of least resistance which is followed by thelines of tension and causes the back section to fold over. In order tominimize or possibly eliminate this folding-over, one embodiment of anabsorbent article includes a pair of fastening tabs (i.e. an engagingmember) 52 and 52′ that are each connected to an elastically elongatableear 42 (respectively 42′). It will be understood that the fastening tab52 is the element of the fastening system that includes a fastener 57and is generally stiffer and less extensible than the elongatable ear. Afastening tab may be a separate web of material joined to the ear suchas a tape tab as represented in FIG. 1A. The fastener 57 may be at leastone of a plurality of hooks protruding away from the fastening tab,loops, an adhesive, a cohesive, or any other fastening member suitableto attach the article about the lower torso of a wearer. A fastening tabcan also be integrally formed with the ear as shown in FIG. 6. For thesake of clarity and brevity, the description of the left fastening taband back ear that follows is applicable to the right fastening tab andback ear and identical elements are referenced in the drawings with thesame number with the prime symbol (for example, 52 and 52′). The leftback ear 42 is a mirror image of the right back ear 42′ and the leftfastening tab 52 is a mirror image of the right fastening tab 52′relative to the absorbent article longitudinal axis. The fastening tab52 represented in FIG. 6 includes an upper edge 152 with an upperproximal end 1152 and a lower edge 252 with a lower proximal end 1252.An elastically elongatable ear 42 includes an upper edge 142 with upperproximal and distal ends 1142, 2142 and a lower edge 242 with lowerproximal and distal ends 1242, 2242. In one embodiment, the distancebetween the upper and lower proximal ends 1152, 1252 of a fastening tab52 is at least 20 mm, at least 30 mm or even at least 40 mm. In oneembodiment, the distance between the upper and lower proximal ends 1152,1252 of a fastening tab 52 is between 20 mm and 80 mm, between 30 mm and70 mm or even between 40 mm and 60 mm. In one embodiment, the back ears42 and 42′ are connected to the chassis such that the transversal line(represented in FIG. 6 by line BB) that includes the upper end 1152 ofthe left fastening tab 52 and the upper end 1152′ of the right fasteningtab 52′ is positioned between the back lateral edge 14 of the chassisand the back edge 528 of the absorbent core. In one embodiment, thelongitudinal distance between the transversal line (B. B) previouslydescribed and the back edge 14 of the chassis is less than 25 mm, lessthan 20 mm, less than 15 mm or even less than 10 mm. In one embodiment,the back ears 42, 42′ are connected to the chassis such that the backedge 528 of the absorbent core is positioned between the transversalline B-B and the transversal line (represented in FIG. 6 by line CC)that includes the lower end 1252 of the left fastening tab 52 and thelower end 1252′ of the right fastening tab 52′. In one embodiment, thedistance between the upper distal end 2142 and the lower distal end 2242of the elongatable back ear 42 is greater than the distance between theupper and lower proximal ends 1152, 1252 of a fastening tab 52. In oneembodiment, the distance between the upper and lower distal ends 2142,2242 of the elongatable back ear 42 is the same as the distance betweenthe upper and lower proximal ends 1152, 1252 of a fastening tab 52.Among other benefits, it is believed that when the distance between theupper and lower distal ends 2142, 2242 of the elongatable back ear 42 isthe same as the distance between the upper and lower proximal ends 1152,1252 of a fastening tab 52, the lateral forces that are applied on thefastening tab 52 are better distributed across the ear 42 and maximizesusage of the ear material. In one embodiment, the distance between theupper and lower proximal ends 1142, 1242 of the back ear 42 is the sameas the distance between the upper and lower distal ends 2142, 2242 ofthe back ear 42. In one embodiment illustrated in FIG. 6, the distancebetween the upper and lower proximal ends 1142, 1242 is greater than thedistance between the upper and lower distal ends 2142, 2242. Among otherbenefits, it is believed that ears that are cut and sized such that thedistance between the upper and lower proximal ends 1142, 1242 is greaterthan the distance between the upper and lower distal ends 2142, 2242provide a more sustained fit around the wearer's legs and hips. In oneembodiment, the distance between the upper and lower proximal ends 1142,1242 of the back ear 42 is at least 5%, at least 10% at least 25% oreven at least 50% greater than the distance between the upper and lowerdistal ends 2142, 2242 of the back ear 42. In one embodiment, the upperedge 152 of the fastening tab 52 is asymmetric to the lower edge 252 ofthe fastening tab relative to the transverse axis Tf of the fasteningtab 52. The transverse axis Tf of the fastening tab 52 is the line thatis equidistant from the upper and lower proximal ends 1152, 1252 of thefastening tab and is perpendicular to the line that includes the upperand lower proximal ends 1152, 1252 of the fastening tab. In oneembodiment, the upper edge 142 of the elongatable back ear 42 isasymmetric to the lower edge 242 of the elongatable back ear relative tothe transverse axis Te of the elongatable back ear. The transverse axisTe of the elongatable back ear 42 is the line that is equidistant fromthe upper and lower proximal ends 1142, 1242 of the back ear and isperpendicular to the line that includes the upper and lower proximalends 1142, 1242 of the back ear 42. In one embodiment, the transverseaxis Tf of the fastening tab 52 overlaps substantially with thetransverse axis Te of the elongatable ear 42. In one embodiment, thetransverse axis Tf of the fastening tab 52 is offset relative to thetransverse axis Te of the elongatable ear 42. The transverse axis Tf ofthe fastening tab 52 and the transverse axis Te of the elongatable ear42 can be separated by a distance of at least 5 mm, at least 10 mm, atleast 15 ram or even at least 20 mm. In one embodiment, the back ears42, 42′ are connected to the chassis such that the lateral back edge 528of the absorbent core 28 is positioned between the lateral back edge 14of the chassis and the transverse axis Te of an elongatable back ear 42.In one embodiment, the back ears 42 and 42′ are connected to the chassissuch that the longitudinal distance between the transverse axis Te ofthe elongatable back ear 42 and the back edge 528 of the absorbent coreis less than 50 mm, less than 40 mm, less than 30 mm or even less than20 mm. In one embodiment, the longitudinal distance between thetransverse axis Te of the elongatable back ear 42 and the back edge 528of the absorbent core is between 0 mm and 50 mm, between 5 mm and 40 mmor even between 10 mm and 30 mm. In one embodiment, the back ears 42,42′ are connected to the chassis such that the transverse Tf axis of afastening tab 52 is positioned between the back edge 14 of the chassisand the back edge 528 of the absorbent core 28. In one embodiment, theback ears 42, 42′ are connected to the chassis such that thelongitudinal distance between the transverse axis Tf of the fasteningtab and the back edge 528 of the absorbent core is less than 50 mm, lessthan 40 mm, less than 30 mm or even less than 15 mm. In one embodiment,the longitudinal distance between the transverse axis Tf of thefastening tab 52 and the back edge 528 of the absorbent core is between0 mm and 30 mm, between 2 mm and 20 mm or even between 2 mm and 15 mm. Amagnified view of an elongatable ear 42 and fastening tab 52 isrepresented in FIG. 7 for clarity and also to illustrate that the ear 42and fastening tab 52 may have a shape other than the shape representedin FIG. 6.

In one embodiment, the portion of the back section 328 of the chassisthat is positioned between the back lateral edge 14 of the chassis andthe back edge 528 of the absorbent core has an average caliper of lessthan 1 mm, less than 0.75 mm, less than 0.5 mm, or even less than 0.25mm.

In one embodiment, the longitudinal distance between the lateral backedge 14 of the chassis and the back edge 528 of the absorbent core isless than 100 mm, less than 90 mm or even less than 80 mm.

In one embodiment, the longitudinal distance between the back lateraledge 14 of the chassis and the back edge 528 of the absorbent core is atleast 10 mm, at least 15 mm or even at least 20 mm. In one embodiment,the back section of the absorbent article has an Average CaliperDifferential of less than 1.25 mm, less than 1 mm, less than 0.75 mm oreven less than 0.5 mm. In one embodiment, the back section of theabsorbent article has an Average Caliper Differential of between 0.1 mmand 1.25 mm, between 0.1 mm and 1 mm, between 0.1 mm and 0.5 mm or evenbetween 0.1 mm and 0.25 mm. The Average Caliper Differential of asection of the an absorbent article can be determined by measuring theaverage caliper of the portion of the back section of the chassispositioned between the back lateral edge of the chassis and the backedge of the absorbent core and the average caliper of the back sectionof the chassis that comprises an absorbent core. The average caliper ofthe portion of the back section of the chassis positioned between theback lateral edge of the chassis and the back edge of the absorbent coreis then deducted from the average caliper of the back section of thechassis that comprises an absorbent core. Without intending to be boundby any theory, it is believed that a back section of an absorbentarticle having such an Average Caliper Differential is less likely tofold-over along the edge of the absorbent core,

Caliper Test

Equipment:

Caliper Instrument One Sokki digital caliper gauge DG-3610 connected toan Ono Sokki linear gauge sensor GS-503

Contact Foot: Flat circular foot with a diameter of 40 mm (+/− (15 mm)

Weigh/Pressure: Total weight of foot and shaft equals 80+/−2 g to equalapproximately 0.1 PSI applied to the sample. A circular weight may beapplied to the foot (i.e., a weight with a slot to facilitateapplication around the shaft) to achieve the target weight.

Ruler—Calibrated metal ruler graduated in mm,

Stopwatch—Accuracy 1 second

Sample Preparation:

1. If the absorbent articles are in their original, unopened package,the sample articles to be tested are removed from the center area of thepackage. If the package contains more than 4 products, the outer mosttwo articles on each side of the package are not used in the testing.

2. If the absorbent article has been out of its original package formore than 15 minutes, place it under an even pressure of 0.345 N/cm2((0.5 lb/in2) for 30 minutes.

3. Physical manipulation of product should be minimal and restrictedonly to necessary sample preparation.

4. As the diapers relax (i.e. expand) when removed from the compressedcondition, the time between removal from the package and the actualcaliper testing may be impact the measurement, Consequently, caliperreadings should be taken approximately 5 to 15 minutes after the productis removed from the package or from under the applied pressure (aspreviously described).

5. Cut or remove any elastic components of the article that prevent thearticle from being laid flat under the caliper foot. These may includeleg cuffs or waistbands. Avoid touching absorbent core area and do notcompress the absorbent core area with the hands

6. Mark the measuring point(s) gently on the diaper with a permanentfelt tip marker.

Caliper Measurement Location:

a) Lay article flat on a counter top,

b) Measure the uncontracted length of the article between the front andback edges along the longitudinal axis of the article. Record thismeasurement.

c) Divide the length by eight.

d) Very gently mark a lateral measurement line across the back portionof the article at a distance of one-eight the article length from theback waist edge of the article, using a permanent felt tip marker.

e) Very gently mark a line along the longitudinal axis of the article inthe back portion of the article using a permanent felt tip marker.

f) At a distance of 20 mm laterally outboard of each side of the lineindicating the longitudinal axis, very gently mark a 40 mm longitudinalmeasurement line parallel with the longitudinal axis and bisected by thelateral measurement line.

g) The intersections of the lateral measurement line and the twolongitudinal measurement lines represent the locations where the centerof the caliper foot will contact during the caliper measurement. Theseintersections are referred to as the “marked measuring points”.

Caliper Measurement Steps:

1. Raise the caliper gauge contact foot and place the article on thecaliper gauge base plate, garment-facing surface side down.

2. With the foot raised, position the article on the base plate in amanner that when lowered, the center of the foot is on one of the markedmeasuring points.

3. Gently lower the foot onto the diaper

4. Read the caliper value to the nearest 0.01 mm, 5 seconds after thefoot comes in contact with the diaper, Record the caliper measurement.

5. Reset the instrument reading to zero after each measurement.

6. Repeat steps 1 through 5 for the second marked measuring point.

Caliper Calculations:

For each article, average the two caliper measurements to calculate therear waist region caliper for that article. Generally, at least fivesamples are measured in this manner for a given product and the rearwaist region calipers may be aggregated to calculate an average andstandard deviation.

Absorbent Core.

In one embodiment, an absorbent article includes an absorbent core 28that is substantially cellulose free. Cross-sectional views of examplesof suitable absorbent cores are schematically represented in FIGS. 8-10.The absorbent core 28 is the element of the absorbent article whoseprimary function is to absorb and retain liquid body exudates.Additional elements may be added between the topsheet and the absorbentcore of an absorbent article to facilitate the acquisition and thedistribution of body exudates. Such elements may include, for example,an acquisition layer and/or a distribution layer as it is well known inthe art. The acquisition and/or distribution layers may themselves besubstantially cellulose free (for example made entirely of a nonwovenmaterial) or include a significant amount of cellulosic material.Although an absorbent core generally includes absorbent materials inparticulate form having a high retention capacity such as, for exampleabsorbent polymers, these materials do not need to be present along theentire length of the absorbent core. It may be advantageous to providean absorbent core with a greater amount of absorbent material in thecrotch area and/or the front waist region in comparison to the backwaist region which may include only a little amount, if any, ofabsorbent polymers. In one embodiment, an absorbent core 28 comprisesfirst and second layers of material 281, 282 and an absorbent material283 disposed between the first and second layers 281, 282. In oneembodiment the first and second layers of material can be a fibrousmaterial chosen from at least one of a nonwoven fibrous web, a wovenfibrous web and a layer of thermoplastic adhesive material. Although thefirst and second layers can be made of a same material, in oneembodiment, the first layer 281 is a nonwoven fibrous web and the secondlayer 282 is a layer of thermoplastic adhesive material. A nonwovenfibrous web 281 can include synthetic fibers, such as mono-constituentfibers of PE, PET and PP, multi-constituent fibers such as side by side,core/sheath or island in the sea type fibers. Such synthetic fibers maybe fanned via a spunbonding process or a meltblowing process. Thenonwoven fibrous web 281 may include a single layer of fibers but it mayalso be advantageous to provide the nonwoven web with multiple layers offibers such as multiple layers of spunbond fibers, multiple layers ofmeltblown fibers or combinations of individual layer(s) of spunbond andmeltblow fibers. In one embodiment, the nonwoven web 281 can be treatedwith an agent (such as a surfactant) to increase the surface energy ofthe fibers of the web. Such an agent renders the nonwoven web morepermeable to liquids such as urine. In another embodiment, the nonwovenweb can be treated with an agent (such as a silicone) that lowers thesurface energy of the fibers of the nonwoven web. Such an agent rendersthe nonwoven web less permeable to liquids such as urine.

The first layer 281 comprises a first surface 2811 and a second surface2812 and at least regions 2813 of the first surface are in direct facialrelationship with a significant amount of absorbent material 283. In oneembodiment an absorbent material is deposited on the first surface 2811in a pattern to form regions 2813 on the first layer 281, which are indirect facial relationship with a significant amount of absorbentpolymer material 283 and regions 2814 on the first web that are infacial relationship with only an insignificant amount of absorbentmaterial. By “direct facial relationship with a significant amount ofabsorbent material” it is meant that some absorbent material isdeposited on top of the regions 2813 at a basis weight of at least 100g/m², at least 250 g/m² or even at least 500 g/m². The pattern mayinclude regions that all have the same shape and dimensions (i.e.projected surface area and/or height). In the alternative the patternmay include regions that have different shape or dimensions to form agradient of regions. At least some of the regions 2813 can have aprojected surface area of between 1 cm² and 150 cm² or even between 5cm² and 100 cm². By “facial relationship with an insignificant amount ofabsorbent material” it is meant that some absorbent material may bedeposited on top of the regions 2814 at a basis weight of less than 100g/m², less than 50 g/m² or even substantially no absorbent material. Atleast some of the regions 2814 can have a projected surface area ofbetween 1 cm² and 150 cm² or even between 5 cm² and 100 cm². Theaggregate projected surface area of all the regions 2813 can representbetween 10% and 90% or even between 25% and 75% of the total projectedsurface area of the first surface 2811 of the first layer 281. In oneembodiment, the second layer 282 is a layer of a thermoplastic adhesivematerial. “Thermoplastic adhesive material” as used herein is understoodto mean a polymer composition from which fibers are formed and appliedto the absorbent material with the intent to immobilize the absorbentmaterial in both the dry and wet state. Non-limiting examples ofthermoplastic adhesive material may comprise a single thermoplasticpolymer or a blend of thermoplastic polymers. The thermoplastic adhesivematerial may also be a hot melt adhesive comprising at least onethermoplastic polymer in combination with other thermoplastic diluentssuch as tackifying resins, plasticizers and additives such asantioxidants. In certain embodiments, the thermoplastic polymer hastypically a molecular weight (Mw) of more than 10,000 and a glasstransition temperature (Tg) usually below room temperature or −6°C.>Tg<16° C. In certain embodiments, typical concentrations of thepolymer in a hot melt are in the range of about 20 to about 40% byweight. Exemplary polymers are (styrenic) block copolymers includingA-B-A triblock structures, A-B diblock structures and (A-B)n radialblock copolymer structures wherein the A blocks are non-elastomericpolymer blocks, typically comprising polystyrene, and the B blocks areunsaturated conjugated diene or (partly) hydrogenated versions of such.The B block is typically isoprene, butadiene, ethylene/butylene(hydrogenated butadiene), ethylene/propylene (hydrogenated isoprene),and mixtures thereof. Other suitable thermoplastic polymers that may beemployed are metallocene polyolefins, which are polymers prepared usingsingle-site or metallocene catalysts. In exemplary embodiments, thetackifying resin has typically a Mw below 5,000 and a Tg usually aboveroom temperature, typical concentrations of the resin in a hot melt arein the range of about 30 to about 60% by weight, and the plasticizer hasa low Mw of typically less than 1,000 and a Tg below room temperature,with a typical concentration of about 0 to about 15%.

The thermoplastic adhesive material 282 can be disposed substantiallyuniformly within the absorbent material 283. In the alternative and asrepresented in FIG. 8, the thermoplastic adhesive material 282 can beprovided as a fibrous layer disposed on top of the absorbent material283 and the regions 2814 of the first surface 2811 that are in facialrelationship with only an insignificant amount of absorbent material. Inone embodiment, a thermoplastic adhesive material is applied at anamount of between 1 and 20 g/m², between 1 and 15 μm² or even between 2and 8 g/m². The discontinuous deposition of absorbent material on thefirst layer 281 imparts an essentially three-dimensional structure tothe fibrous layer of thermoplastic material 282. In other words, thelayer of thermoplastic adhesive material follows the topographyresulting from the absorbent material 283 deposited on the firstnonwoven fibrous web 281 and the regions 2814 that only includeinsignificant amounts of absorbent material. Without intending to bebound by any theory, it is believed that the thermoplastic adhesivematerials disclosed herein enhance immobilization of the absorbentmaterial in a dry and wet state.

In one embodiment, the absorbent core 28 may further comprise a secondlayer of a nonwoven fibrous material 284 as represented in FIG. 9. Thissecond layer may be provided of the same material as the nonwovenfibrous layer 281, or in the alternative may be provided from adifferent material. It may be advantageous for the first and secondnonwoven fibrous layers 281, 284 to be different in order to providethese layers with different functionalities. In one embodiment, thesurface energy of the first nonwoven layer can be different than thesurface energy of the second nonwoven layer. In one embodiment, thesurface energy of the second nonwoven layer is greater than the surfaceenergy of the first nonwoven layer. Among over benefits, it is believedthat when the surface energy of the second nonwoven layer is greaterthan the surface energy of the first nonwoven layer, liquids such asurine will be able to penetrate the second nonwoven layer more easily inorder to reach and be retained by the absorbent material while at thesame time reducing the chances that the liquid may penetrate and gothrough the first layer. This may be particularly advantageous when thefirst nonwoven layer is disposed against the backsheet of an absorbentarticle. The different surface energies of each layer may be obtained,for example, by applying a different amount of an agent such as asurfactant to the second nonwoven layer than the amount of surfactant(if any) applied to the first nonwoven layer. This may also be achievedby applying a different type of surfactant to the second nonwoven layerthan the surfactant applied to the first nonwoven layer. This may stillbe achieved by applying a material to the first nonwoven layer thatlowers its surface energy. In addition to having different surfaceenergies, or in the alternative, the first and second nonwoven fibrouslayers 281, 284 may also be different structurally. In one embodiment,the first nonwoven layer 281 may include different layers of fibers thanthe second nonwoven layer. For example, the second nonwoven layer 284may only include one or more layers of spunbond fibers whereas the firstnonwoven layer 281 includes one or more layers of spundbond fibers andone or more layers of meltblown fibers. In another embodiment, bothnonwoven fibrous layers 281, 284 may include one or more layers ofspunbond fibers and one or more layers of meltblow fibers but the firstand second layers 281, 284 differ in terms of at least one of thechemical composition of the fibers used to form the nonwoven material,the denier of the fibers and/or the basis weight of the nonwovenmaterial. In addition to or in the alternative than the above the firstand second nonwoven layers 281, 284 may also differ in terms of at leastone of their respective hydrohead values, their respective porosity,their respective Frazier permeability and their respective tensileproperties. The second nonwoven layer 284 may applied directly on top ofthe first nonwoven layer 281, the absorbent material 283 and thethermoplastic adhesive material 282. As a result, the first and secondnonwoven layers 281 and 284 further encapsulate and immobilize theabsorbent material 283.

The regions 2813 may have any suitable shape in the x-y dimension (i.e.the horizontal plane) of the absorbent core. In one embodiment, theregions 2813 form a pattern of disc that are spread on the first surfaceof the first web 281. In one embodiment, the regions 2813 form a patternof longitudinal “strips” or “bars” that extend continuously along thelongitudinal axis of the absorbent core (i.e. along the y dimension) andare spread apart from each other. In one embodiment, the regions 2813form a pattern of longitudinal “strips” or “bars” that extendcontinuously along the transverse axis of the absorbent core (i.e. alongthe x dimension). In an alternative embodiment, these strips may be arearranged to form an angle of at between 1.0 and 90 degrees, between 20and 80 degrees, between 30 and 60 degrees, or even 45 degrees relativeto the longitudinal axis of the absorbent article. In one embodiment, a“strip” or “bar” can have a substantially rectangular shape with thelongest side of the rectangle being at least twice, 5 times, even 25times, or even 50 times as long as the shortest side of the rectangleformed by the “strip” or “bar.”

In one embodiment schematically represented in FIG. 10, the secondnonwoven layer 284 has a first surface 2841 and a second surface 2842and an absorbent material 283 applied to its first surface 2841 in orderto form a pattern of regions 2843 that are in direct facial relationshipwith a significant amount of absorbent material 283 and regions 2844 onthe first surface 2841 that are in facial relationship with only aninsignificant amount of absorbent material as previously discussed. Inone embodiment, a thermoplastic adhesive material 285 may further beapplied on top of the second nonwoven layer 284 as previously discussedin the context of the first web/absorbent material/thermoplasticadhesive material composite. The second nonwoven layer 284 may then beapplied on top of the first nonwoven layer 281. In one embodiment, thepattern of absorbent material present on the second nonwoven layer 284may be the same as the pattern of absorbent material present on thefirst nonwoven layer 281. In an other embodiment, the patterns ofabsorbent material that are present on the first and second nonwovenlayers are different in terms of at least one of the shape of theregions, the projected surface areas of the regions, the amount ofabsorbent material present on the regions and the type of absorbentmaterial present on the regions. It is believed that when the patternsof absorbent material that are present on the first and second nonwovenlayers are different, each layer/absorbent composite may have differentfunctionalities such as for example, different absorbent capacitiesand/or different acquisition rates of liquids. It can be beneficial forexample to provide an absorbent core with a structure where the secondpattern formed by the regions 2843 of absorbent material (i.e. on thesecond nonwoven layer 284) exhibits a slower acquisition rate than thefirst pattern of regions 2813 of absorbent material in order to allowliquids, such as urine, to reach and be absorbed by the absorbentmaterial deposited on the first nonwoven layer 281 before expansion ofthe absorbent material in the regions 2843. Such a structure avoids anysignificant gel blocking by the absorbent material present in theregions 2843. It can also be advantageous to apply the secondlayer/absorbent material/thermoplastic adhesive material composite insuch a way that at least some of or even all of the regions 2813 of thefirst nonwoven layer 281 that are in direct facial relationship with asignificant amount of absorbent material are also in substantial facialrelationship with corresponding regions 2844 of the second web 284,which are in facial relationship with an insignificant amount ofabsorbent material.

The absorbent core 28 may also comprise an auxiliary adhesive which isnot illustrated in the figures. The auxiliary adhesive may be depositedon at least one of or even both the first and second nonwoven layers281, 284 before application of the absorbent material 283 in order toenhance adhesion of the absorbent material as well as adhesion of thethermoplastic adhesive material 282, 285 to the respective nonwovenlayers 281, 284. The auxiliary adhesive may also aid in immobilizing theabsorbent material and may comprise the same thermoplastic adhesivematerial as described hereinabove or may also comprise other adhesivesincluding but not limited to sprayahle hot melt adhesives, such as RB.Fuller Co. (St. Paul, Minn.) Product No. HL-1620-B. The auxiliaryadhesive may be applied to the nonwoven layers 281, 284 by any suitablemeans, but according to certain embodiments, may be applied in about 0.5to about 1 mm wide slots spaced about 0.5 to about 2 mm apart.Non-limiting examples of suitable absorbent material 283 includeabsorbent polymer material such as cross linked polymeric materials thatcan absorb at least 5 times their weight of an aqueous 0.9% salinesolution as measured using the Centrifuge Retention Capacity test (Edana441.2-01). In one embodiment, the absorbent material 283 is absorbentpolymer material which is in particulate form so as to be flowable inthe dry state.

As previously discussed, the absorbent material 283 present in theabsorbent cores 28 of an absorbent article and more particularlyillustrated in FIGS. 8-10, does not need to be present along the entirelength of the absorbent core. In one embodiment, the back section 328 ofan absorbent article includes an insignificant amount of absorbentmaterial 283 whereas at least the middle 228 and/or the front section128 include a greater amount of absorbent material than the back section328. For example, the back section 328 may include less than 5 grams, orless than 3 grams, less than 2 grams or even less than 1 g of aparticulate absorbent polymer material. The middle section 228 mayinclude at least 5 grams, or at least 8 grams, or even at least 10 gramsof a particulate absorbent polymer material. The front section 128 mayinclude between 1 and 10 grams, or between 2 and 8 grams of aparticulate absorbent polymer material.

In addition, it should be noted that the front and back edges of theabsorbent chassis of the article are shown as being linear in FIGS. 1Athrough 3B. However, either the back and/or the front edges may have ashape other than linear, Suitable non-linear shapes are disclosed inU.S. Pat. No. 7,361,167 issued on Apr. 22, 2008, to Erickson et al. andassigned to The Procter and Gamble Company.

In one embodiment, at least one of, or even both the nonwoven layers 281and 284 of an absorbent core extend from a portion of the front section128, which is proximate the front edge of the absorbent article, to aportion of the back section 328 (inclusive of the middle section 228),which is proximate the back edge of the absorbent article. The absorbentmaterial 283 may be present in the absorbent core along substantiallythe whole length of the nonwoven layers 281 and 284 as schematicallyrepresented in FIG. 11 with the absorbent material 283 represented withangled lines, it may be advantageous to include absorbent material 283in the front and middle sections 128, 228 of the absorbent article butto limit the overall amount of absorbent material in the back section ofthe absorbent article such that the transverse axis Te of the earsand/or Tf of the fastening tabs go through a region of the absorbentcore, which includes less absorbent material than the front and middlesections 128, 228. In one embodiment schematically represented in FIG.12, the absorbent material 283 may be applied on the portion of theabsorbent core present in the back section but at a lower basis weightthan the absorbent material present in the middle section 228. Inanother embodiment schematically represented in FIG. 13, the absorbentmaterial 283 may be disposed in only a portion of the back section 328leaving the portion of the back section proximate the back edge of theabsorbent article with only an insignificant amount of absorbentmaterial. In yet another embodiment schematically represented in FIG.14, the portion of the absorbent core 28 disposed in the back section328 includes an insignificant amount of absorbent material or even noabsorbent material. In one embodiment schematically represented in FIG.15, at least one of, or even both the nonwoven layers 281 and 284 of anabsorbent core extend from a portion of the front section 128, which isproximate the front edge of the absorbent article, to a portion of theback section 328 (inclusive of the middle section 228), which isproximate the line that separates the middle and back sections 328. Anabsorbent material 283 is disposed between the nonwoven layers 281, 284leaving a substantially portion of the back section 328 with essentiallyno absorbent core. Among other benefits, it is believed that limitingthe overall amount of absorbent material 283 in the back section 328renders the back section 328 more flexible and allows the back sectionto better conform and remain in close contact with the skin of thewearer.

Peak Bending Force.

As previously discussed, it can be advantageous to provide an absorbentarticle having at least a back section that is flexible. This may beaccomplished by significantly reducing the amount of cellulosic materialpresent in the portion of the absorbent core present in the back sectionof the absorbent article. It is believed that a cellulosing material canstiffen regions of the article where it is present, in particular when astack of folded absorbent articles are compressed to be packaged.Additional flexibility may further be obtained by significantly reducingthe amount of absorbent material present in the portion of the absorbentcore, which is present in the back section of the article. Furtherflexibility may also be obtained by reducing the amount of thermoplasticadhesive material present in the portion of the absorbent core, which ispresent in the back section of the article. In one embodiment, theAverage Peak Bending Force of the rear region of back section 38 of anabsorbent article is less than 0.08N, less than 0.07N, less than 0.06Nor even less than 0.05N.

Bending Stiffness Measurement Method

Peak Bending Force and Bending Stiffness are measured using a constantrate of extension tensile tester with computer interface (a suitableinstrument is an MTS Alliance under TestWorks 4 software, as availablefrom MTS Systems Corp., Eden Prairie, Minn.) fitted with a 10 N loadcell. A plunger blade 2100, shown in FIG. 9 (front view) and FIG. 10(side view), is used for the upper movable test fixture. Base supportplatforms 2200, shown in FIG. 8, are used as the lower stationary testfixture. All testing is performed in a conditioned room maintained atabout 23° C.±2 C and about 50%±2% relative humidity.

Components of the plunger 2100 are made of a light weight material suchas aluminum to maximize the available load cell capacity. The shaft 2101is machined to fit the tensile tester and has a locking collar 2102 tostabilize the plunger and maintain alignment orthogonal to base supportplatforms 2204. The blade 2103, is 115 mm long 2108 by 65 mm high 2107by 3.25 mm wide 2109, and has a material contact edge with a continuousradius of 1.625 mm. The bracket 2104 is fitted with set screws 2105 thatare used to level the blade and a main set screw 2106 to firmly hold itin place after adjustment.

The bottom fixture 2200 is attached to the tensile tester with the shaft2201 and locking collar 2202. Two horizontally movable support platforms2204 are mounted on a rail 2203. Each test surface 2205 is 85 mm wide2206 by 115 mm long (into plane of drawing) and made of polishedstainless steel so as to have a minimal coefficient of friction. Eachplatform has a digital position monitor 2208 which reads the individualplatform positions, and set screws 2207 to lock their position afteradjustment. The two platforms 2204 are square at the gap edge and theplate edges should be parallel front to back. The two platforms form agap 2209 with an adjustable gap width 2210.

Accurately (±0.02 mm) align the plunger blade 2103 so that it isorthogonal to the top surface of the support platforms 2204 and exhibitsno skew relative to their gap edges. Using the position monitors 2208,accurately set the gap 2210 to 25.00±0.02 mm between the two gap edgesof the support platforms 2204, with the plunger blade 2103 accurately(±0.02 mm) centered in the gap. Set the gauge length from the bottom ofthe plunger blade 2103 to the top surface of the support platform 2204to 15 mm. Program the tensile tester to perform a compression test,collecting force and extension data at an acquisition rate of 400 Hz asthe crosshead lowers at a rate of 500 mm/min for a total distance of 35mm.

Precondition samples at about 23° C.±2° C. and about 50%±2% relativehumidity for 2 hours prior to testing. The absorbent article is unfoldedand placed with the wearer-facing surface facing upward. Using scissorscut the elastics along the longitudinal edges of the article at aninterval of approximately 2 cm, such that the article can be laid flat.With a calibrated ruler, measure the longitudinal length of the articleto the nearest 1 mm. Measure a distance equal to 20% of the article'slongitudinal length, originating from the back waist edge of thearticle, along the longitudinal axis of the article, Mark the surface ofthe article at this intersection. With a hydraulic press and cutting die(63.5 mm square ±0.1 mm and 25 mm deep), cut a specimen centered on thismark through all the layers of the absorbent article with the specimen'scut edges parallel and perpendicular to the longitudinal and lateralaxis of the article.

Place the specimen flat onto the surface of the support platform 2204over the gap 2209 with the wearer-facing surface facing upward. Centerthe specimen 1009 under the blade. The specimen is placed such that thedirection corresponding to the lateral axis of the absorptive article itwas harvested from is parallel to the length of the blade. Zero the loadcell; start the tensile tester and the data acquisition.

Program the software to calculate the maximum Peak. Bending Force (N)and

Stiffness (N/m) from the constructed force (N) verses extension (m)curve. Stiffness is calculated as the slope of the bendingforce/extension curve for the linear region of the curve (see FIG. 11),using a minimum line segment of at least 25% of the total peak bendingforce to calculate the slope.

Report Peak Bending Force to the nearest 0.01 N and the BendingStiffness to the nearest 0.1 N/m, and record the results. Repeat thetest and record the results for 10 samples. Calculate the average PeakBending Force and average Bending Stiffness.

Examples

Average Peak Bending Standard Product name Force at Waist (N) DeviationExample A 0.06 0.02 Pampers Cruisers (Size 4) 0.14 0.03 Pampers Easy Ups(Size 5) 0.82 0.1 Pampers Baby Dry (Size 5) 0.12 0.03 Luvs (Size 4) 0.100.02 Luvs (Size 2) 0.08 0.01 Huggies Little Movers (Size 5) 0.64 0.06Huggies Snug & Dry (Size 5) 0.96 0.28 Huggies Pull Ups (Size 3T/3T) 0.820.21 Target Brand (Size 5) 0.3 0.03 Pampers and Luvs products aremanufactured by The Procter & Gamble Company Huggies products aremanufactured by Kimberly-Clark Example A is representative of oneembodiment of the invention and include an absorbent core described inthe context of FIG. 10.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any definitionor meaning of a term in this written document conflicts with anydefinition or meaning of the term in a document incorporated byreference, the definition or meaning assigned to the term in thisdocument shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It should beapparent that combinations of such embodiments and features are possibleand can result in executions within the scope of this invention. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A disposable absorbent article comprising: a) a chassis having afront region with a front edge, a rear region with a back edge, a crotchregion between the front region and the rear region, and a pair ofopposing longitudinal edges, said chassis comprising an absorbent corehaving front and back edges; b) first and second elastically elongatableears, each of said first and second ears having upper and lower edgesand a transverse axis, each of said upper and lower edges havingproximal and distal ends, said first and second ears defining a backsection of said absorbent article that is present between said back edgeof said chassis and a line connecting the respective lower ends of thelower edge of said first and second ears, and c) first and secondfastening tabs respectively connected said first and second elasticallyelongatable ears, each of said first and second fastening tabs havingupper and lower edges and a transverse axis, each of said upper andlower edges having a proximal end, wherein said back section of saidabsorbent article includes a portion of said absorbent core having anaverage caliper of less than about 1.5 mm and wherein said first andsecond elastically elongatable ears are connected to said chassis suchthat the transverse axis of each of said first and second fastening tabis disposed between said back edge of the chassis and said back edge ofsaid absorbent core.
 2. The disposable absorbent article of claim 1wherein said absorbent core contains less than 10% by weight of theabsorbent core of cellulosic fibers.
 3. The disposable absorbent articleof claim 1 wherein the upper and lower edges of said fastening tabs areasymmetric relative to the transverse axis of the fastening tabs.
 4. Thedisposable absorbent article of claim 1 wherein the elasticallyelongatable ears have a transverse axis that is separated from the backedge of the absorbent core by a distance of less than about 50 mm. 5.The disposable absorbent article of claim 4 wherein the transverse axisof the elongatable ears is offset relative to the transverse axis of thefastening tabs.
 6. The disposable absorbent article of claim 1 whereinthe back edge of the chassis and the back edge of the absorbent core areseparated by a longitudinal distance of less than about 100 mm.
 7. Thedisposable absorbent article of claim 1 wherein the transverse axis ofthe fastening tab overlaps substantially with the transverse axis of theelongatable ear.
 8. The disposable absorbent article of claim 1 whereinsaid absorbent core is substantially cellulose free.
 9. The disposableabsorbent article of claim 8 wherein said absorbent core contains lessthan about 5% by weight of the absorbent core of cellulosic fibers. 10.The disposable absorbent article of claim 8 wherein said absorbent corecomprises a first layer of a nonwoven fibrous material having upper andlower surfaces, a layer of a thermoplastic adhesive material and anabsorbent material between the upper surface of the first layer of thenonwoven fibrous material and the layer of thermoplastic adhesivematerial.
 11. The disposable absorbent article of claim 10 wherein theupper surface of the first layer of nonwoven material comprises aplurality of regions that are each in direct facial relationship with asignificant amount of absorbent material.
 12. The disposable absorbentarticle of claim 11 wherein said upper surface of said first layer ofnonwoven fibrous material comprises a plurality of region that are eachin facial relationship with an insignificant amount of absorbentmaterial.
 13. The disposable absorbent article of claim 12 wherein saidabsorbent core further comprises a second layer of a nonwoven fibrousmaterial having upper and lower surfaces such that said absorbentmaterial and said layer of thermoplastic adhesive material are betweensaid upper surface of said first layer of nonwoven fibrous material andsaid second layer of said nonwoven fibrous material.
 14. The disposableabsorbent article of claim 13 wherein the lower surface of the secondlayer of nonwoven material comprises a plurality of regions that areeach in direct facial relationship with a significant amount ofabsorbent material.
 15. The disposable absorbent article of claim 14wherein said lower surface of said second layer of nonwoven fibrousmaterial comprises a plurality of region that are each in facialrelationship with an insignificant amount of absorbent material.
 16. Thedisposable absorbent article of claim 15 wherein at least some of theregions of said upper surface of the first nonwoven fibrous materialthat are in direct facial relationship with an absorbent material are indirect facial relationship with at least corresponding regions of thelower surface of the second nonwoven fibrous material that are in facialrelationship with an insignificant amount of absorbent material.
 17. Thedisposable absorbent article of claim 13 wherein said first layer ofnonwoven fibrous material and said second layer of nonwoven fibrousmaterial are made of different nonwoven materials.
 18. The disposableabsorbent article of claim 13 wherein said first layer of nonwovenfibrous material and said second layer of nonwoven fibrous material eachhave a surface energy and wherein the surface energy of said first layeris different from the surface energy of said second layer.
 19. Thedisposable absorbent article of claim 18 wherein said second layer ofnonwoven fibrous material comprises a surfactant.
 20. The disposableabsorbent article of claim 19 wherein said article comprises a middlesection having an average caliper that is greater than the averagecaliper of said back section.